Pleated ballistic package for soft body armor

ABSTRACT

A ballistic vest having a ballistic panel including a plurality of layers of ballistic material, wherein a portion of the layers of ballistic material include a series of folded pleats arranged at selected angles and intervals along the layer and sewn along their length.

FIELD OF THE INVENTION

This invention relates to protective vests, and more particularly to a ballistic performance and trauma reduction system for soft body armor, which incorporates a ballistic package having pleats stitched in one or more layers of ballistic fabric sheet.

BACKGROUND OF THE INVENTION

Ballistic vests have saved the lives of many law enforcement officers in recent years. As a result, law enforcement agencies have made it mandatory for their officers to wear ballistic vests while on duty.

Ballistic vests are available as a protective panel having overlying layers of a fabric made from woven or non-woven high tensile strength fibers. Woven fabrics from an aramid fiber known as Kevlar, for example, have been used successfully in ballistic vests because of the high energy absorption properties of the fabric material. Comfort of the ballistic vest is extremely important, especially to law enforcement officers, because of the heat build up that occurs from wearing a heavy and inflexible vest for long hours while on duty. Resistance to projectile penetration is a principle factor in designing a ballistic vest; and added protective layers can offer greater protection against projectiles having the higher threat levels, but added protective layers also add undesirable weight and inflexibility of the vests.

In addition to woven Kevlar fabric layers, ballistic vests have been made from other high strength fibers and non-woven composites to reduce weight and improve flexibility of the vests. However, ballistic vests using the lighter, more flexible materials must offer the required minimum levels of protection against penetration by different types of projectiles. The more flexible the ballistic fabrics are, the more bunching and backface deformation occurs upon impact from a projectile. A vest must not be too flexible where it cannot protect the wearer.

Ballistic vests are regularly certified by subjecting them to ballistics testing to measure their ability to protect against different projectiles fired from different types of weapons at various angles. One ballistic test commonly used in the industry is the National Institute of Justice (NIJ) Standard 0101.03 Threat Level IIIA. Which, in general terms, is a high performance standard requiring that the ballistic vests prevent penetration of specified 0.44 Magnum and 9 mm rounds fired at a velocity of at least 1,400 feet per second. In addition to prevent such projectile penetration, “backface deformation” is also a required test factor in the certification test. Backface deformation measures the trauma level experienced by a projectile that does not penetrate the tests panel.

There is a need to provide a ballistic vest that is reasonably light in weight, is thin and is comfortable, and is also capable of meeting the high performance projectile specifications of certification testing. Providing such a vest at a reasonably low cost for the comparable high performance level also is a desirable objective. Consequently, a need exists for an improved soft body armor design, namely, to improve ballistic performance and comfort and to reduce weight while simultaneously reducing blunt trauma.

SUMMARY OF THE INVENTION

The present invention provides a ballistic vest of the soft body armor type comprising for example, a plurality of over-laying first flexible layers arranged in a stack on a strike side of the vest, and a plurality of overlying second flexible layers arranged in a stack on a body side of the vest. Each first flexible layer may comprise a thin, flexible, woven fabric layer made of high tensile strength polymeric fibers. The individual woven fabric layers form a soft, flexible woven fabric first panel for the vest. Each second flexible layer may comprise a thin, flexible imperforate fiber-reinforced sheet comprising an array of fibers embedded in a thermoplastic resin matrix that forms each laminate film sheet. Although this is one example of a ballistics package, any type and number of ballistics packages which meet any threat level are contemplated for use in the present invention. The vests of the present invention preferably is designed to be concealable, however it is to be understood that the inventive concepts are equally applicable to ballistic vests which are worn on the outside of the wearers' clothing or uniforms. The ballistics package of the present invention is equally applicable to other types of protective garments other than vests.

The ballistic vest of the present invention incorporates nylon hook fasteners to fasten the front panel to the back panel, and are attached to strapping or conventional elastic. Vests, or other garments of the present invention can also use buckles, zippers and other fastening systems.

More particularly, the ballistic vest of the present invention incorporates within the ballistics package a series of folded pleats at selected angles and intervals that are stitched in one or more individual layers of the woven or non-woven ballistic fabric contained within the package. Energy is transmitted through the ballistic layers to the pleats thereby improving ballistic performance and reducing trauma to the wearer's body, resulting in safer and lighter soft body armor. The pleats absorb energy and shock from the projectile by adding crumple resistance to help dissipate ballistic energy and by expanding. During this expansion energy is consumed by breakage of sewing thread running the length of the pleat.

The use of a series of folded pleats at selected angles and intervals on individual plies of the present invention permits the production of lower costs and lighter weight ballistic vests. The pleats reduce the amount of depression or backface trauma caused by stopping a projectile. Consequently, injury caused by blunt force trauma is reduced, thereby improving safety of the vests. Because the pleats reduce the amount of material travel, the amount of ballistic materials can be reduced, thereby providing an effective ballistic system that is lighter in weight which improves wear comfort and reduces the overall costs for manufacturing the vests.

Preferably the pleats are sewn in one or more sheets within the multiple plies of ballistic fabric contained within the ballistic package. The pleats are sewn with one or more lines of stitching and can be vertical, horizontal or at any angle. The ballistic fabric containing the pleats can consist of woven or non-woven Kevlar, Spectra Nylon or Zylon fibers or other known ballistic material.

In a ballistic event, the projectile strikes the ballistics material and energy is transferred to the pleats via the fibers in the ballistic fabrics. When the bullet contacts the surface, it expands, twists and becomes entangled in the fibers and tension is put on the pleats. The pleats reduce the amount of depression of backface trauma caused by the slowing projectile. Energy used to crumple or expand and break stitching is absorbed as opposed to breaking through the ballistic fabric, thereby increasing the bullet resistance of the armor.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other features and advantages of the present invention will be more fully understood by reference to the drawings and following detailed description wherein:

FIG. 1 is a front view of a ballistic vest of the present invention;

FIG. 2 is a back view of the ballistic vest of FIG. 1.;

FIG. 3 is a partial cross-sectional view of the front panel of the ballistic vest of the present invention;

FIG. 4 is a detail of FIG. 1 illustrating access to the ballistics panel or package; and

FIG. 5 is a partial perspective detail view of individual sheets of pleated ballistic material contained within the ballistic package of the vest of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

A ballistic vest 10 of the present invention is shown in FIGS. 1 and 2. The ballistic vest 10 is a concealable vest of the soft body armor type commonly worn by law enforcement officers. The ballistic vest includes a front panel 12 and a rear panel 14. The front panel 12 protects the chest and stomach of the wearer while the rear panel 14 protects the back of the wearer.

The front panel 12 may include a center panel 16 and hook compatible fabric located on the top 18 and sides 20 of the front panel 12. Top 18 and sides 20 provide a large area for hook fasteners 22 to secure the front panel and rear panel together around the wearer. Top 18 and sides 20 allow for placement of fasteners 22 at any location to provide an optimal fit for the particular wearer. Straps 24 located at the top and sides of the ballistic vest are attached to the fasteners 22 to secure the front and rear panels together. As seen best in FIG. 2, straps 24 for connecting the top of the front and rear panels can be typically sewn to the rear panel, or as with straps 24 located at the sides of the ballistic vests, can be inserted into a pocket 26 which includes a section of hook fasteners 28, sewn within the pocket, for connection of the straps 24. The pocket arrangement for the straps can be located at the top, sides or both locations of the vest. As indicated by the direction arrows 30, the straps 24 provide for multi-directional adjustment.

As shown as in FIG. 3, the front panel, as well as the rear panel, includes a lining material 40 which is adjacent the body 42 of the wearer and extends around the edge of the panel to the outside of the ballistic vest. The material can be perforated or of solid construction and is a moisture absorbing material which wicks moisture away from the body and around to the outside of the vest for evaporation. Contained within the lining material 40 is the ballistic panel or package 42 which comprises the individual layers of ballistic material 44 located within a covering layer 46. Layer 46 comprises a top layer 48 and a bottom layer 50 stitched together at internal seam 52. Gaps are shown between lining material 40 and top and bottom layers 48 and 50, and between layers 48 and 50 and ballistic material 44 only so that these components can be easily illustrated. It is to be understood that in the actual vest no gaps are present so that ballistic protection extends virtually from edge to edge in the front and rear panels. As shown in FIGS. 1 and 2, the lining material 40 extends around the outside surface of the vest and is sewn to the outside surface of the front and rear panels 18 and 20 to form a seam 54 which allows the ballistics package to extend all the way to the edge of the front and rear panels.

As shown in FIG. 4, the front panel 12 includes an opening 56 for access to the ballistics panel 58. The opening is positioned on the outside of the front panel to produce a smooth surface against the body. A zipper 60 or other suitable closing mechanism extends across the width of the opening. The zipper permits easy access to remove the ballistics panel or package.

As seen in FIG. 2, the ballistic vest includes visual inspection ports 62 positioned on the exterior of the garment. As shown in FIG. 1, retention tails 64 and 66 are sewn to the lower edge 38 of the front and rear panels respectively. Preferably the tails are constructed of stretchable fabrics or meshes which are tucked into a wearer's trousers to hold the vest down during movement.

As shown in FIG. 5, the ballistic vest of the present invention includes a series of Z-shaped folded pleats 70 in one or more layers of ballistic material 44 a and 44 b the pleats on ballistic layer 44 a are vertically oriented and pleats 70 on ballistic layer 44 b are horizontally oriented. In addition, the pleats 70 can be positioned along angles from horizontal or vertical. The pleats can be spaced uniformly and in series or non-uniformly and in intervals. The number of pleats, their orientation and spacing can be varied to accommodate different threat levels. In addition, the number of layers of ballistic material having pleats can vary and can have non-pleated layers of ballistic material positioned in between layers having pleats. For example, a particular ballistic package can employ a series of vertically oriented pleated ballistic sheets on every other ply and horizontally oriented pleats on the plies in between. Depending upon the particular application, the pleated or non-pleated ballistic material layers can be woven or non-woven fabric depending upon the particular application.

The pleats are formed by folding the individual layer of ballistic material and sewing the pleat with a line of stitching 72. The pleats absorb shock of the ballistic projectile by adding crumple resistance to the dissipate ballistic energy. The pleats can expand upon impact by the projectile which consumes ballistic energy by breakage of the sewing thread running the length of the pleat. Preferably, the stitching for a plastic sheet ballistic layer is Kevlar stitching and for a woven ballistic sheet the stitching can be nylon as well as Kevlar. During a ballistic event, energy is transmitted though the pleats on the individual ballistic sheets, improving ballistic performance and reducing trauma to the wearers body, resulting in safer and lighter soft body armor.

Although the present invention has been shown and illustrated with respect to an embodiment thereof, the invention is not to be so limited since changes and modifications can be made therein which are within the scope of the invention as hereinafter claimed. For example, the pleats are Z-shaped pleats which include two folds, however the pleats could be more accordion shape having four or more folds. 

1. A ballistic panel for use in ballistic apparel comprising a plurality of layers of ballistic material wherein at least one of the layers includes a series of folded pleats arranged at intervals along the layer.
 2. The panel of claim 1 wherein there are multiple layers of ballistic material including a series of folded pleats.
 3. The panel of claim 1 wherein the pleats are sewn along their length.
 4. The panel of claim 1 wherein the pleats are arranged horizontally along the layer.
 5. The panel of claim 1 wherein the pleats are arranged vertically along the layer.
 6. The panel of claim 1 wherein the pleats are arranged at an angle along the layer.
 7. The panel of claim 1 wherein a portion of the layers are woven ballistic material.
 8. The panel of claim 1 wherein a portion of the layers are non-woven ballistic material.
 9. The panel of claim 1 wherein the pleats are Z-shaped.
 10. A ballistic vest comprising: a front panel; a rear panel; at least one of the front and rear panels having a ballistic package comprising a plurality of layers of ballistic material wherein at least one of the layers includes a series of folded pleats arranged along the layer; and connectors for attaching the front and rear panels together.
 11. The vest of claim 10 wherein multiple layers of ballistic material include a series of folded pleats.
 12. The vest of claim 10 wherein the pleats are sewn along their length.
 13. The vest of claim 10 wherein the pleats are arranged horizontally along the layer.
 14. The vest of claim 10 wherein the pleats are arranged vertically along the layer.
 15. The vest of claim 10 wherein the pleats are arranged at an angle along the layer.
 16. The vest of claim 10 wherein a portion of the layers are woven ballistic material.
 17. The vest of claim 10 wherein a portion of the layers are non-woven ballistic material.
 18. The vest of claim 10 wherein the pleats are Z-shaped.
 19. The vest of claim 10 wherein there are a plurality of layers having vertically oriented pleats interposed between layers having horizontally oriented pleats.
 20. The vest of claim 10 wherein there are layers of ballistic material having no pleats positioned between layers of ballistic material having pleats. 